VW Golf, GTI, Jetta Repair Manual 1999-2005

This DIY Haynes repair and service manual, covers 1999-2005 VW Golf, GTI, and Jetta, with 4-cylinder gasoline engines, and TDI Diesel engines, 1999-2004. Note: this manual DOES NOT include information specific to models with the VR6 engine, 5-cylinder engine, 2004 and later TDI-PD diesel engine, R32 AWD models, or early 1999 models based on the A3 platform.
Book Excerpt: VW Golf, GTI, Jetta Repair Manual 1999-2005: 4-Cylinder Gas Engines, TDI Diesel 1999-2004 PART B: DIESEL ENGINE

VALVE SPRINGS, RETAINERS AND SEALS | REPLACEMENT
(Refer to illustrations 7.7, 7.12a, 7.12b, 7.12c, 7.13 and 7.14) NOTE: Broken valve springs and defective valve stem seals can be replaced without removing the cylinder heads. Some special tools are normally required to perform this operation, so read through this Section carefully and rent or buy the tools before beginning the job.

1. Remove the valve cover, referring to Section 4.
2. Refer to Section 6 and remove the camshaft and lifters. Remove the glow plugs (see Chapter 4B).
3. Turn the crankshaft until the piston in the affected cylinder is at Top Dead Center (TDC) on the compression stroke (see Section 3 for instructions). If you're replacing all of the valve stem seals, begin with cylinder number one and work on the valves for one cylinder at a time. Move from cylinder-to-cylinder following the firing order sequence (see the Specifications listed at the beginning of this Chapter).
4. A compressed air source is not necessary on diesel engines, since valve to piston clearance is smaller than normal compared to a typical gasoline engine. The valves will be held in place by the piston crown when the cylinder is at TDC.
5. Stuff shop rags into the cylinder head holes around the valves to prevent parts and tools from falling into the engine.
6. Using a socket and a hammer, gently tap on the top of each valve spring retainer several times. This will break the bond between the valve keeper and the spring retainer and allow the keeper to separate from the valve spring retainer as the valve spring is compressed.
7. Use a valve spring compressor to compress the spring. Remove the keepers with small needle-nose pliers or a magnet (see illustration). Note: Several different types of tools are available for compressing the valve springs with the head in place. Be sure to purchase or rent the "Import type" that bolts to the top of the cylinder head. This type uses a support bar across the cylinder head for leverage as the valve spring is compressed. The lack of clearance surrounding the valve springs on these engines prohibits typical types of valve spring compressors from being used.
8. Remove the valve spring and retainer.
9. Remove the old valve stem seals, noting the differences between the intake and exhaust seals, if any.
10. Inspect the valve stem for damage. Rotate the valve in the guide and check the end of eccentric movement, which would indicate that the valve is bent.

SUSPENSION AND STEERING SYSTEMS

GENERAL INFORMATION (Refer to illustration 1.1) FRONT SUSPENSION The independent front suspension is of the MacPherson strut type, incorporating coil springs and integral telescopic shock absorbers. The MacPherson struts are located by transverse control arms, which use rubber inner mounting bushings, and incorporate a balljoint at the outer ends. The front steering knuckles, which carry the wheel bearings, brake calipers and the hub/disc assemblies, are bolted to the MacPherson struts, and connected to the control arms through the balljoints. A stabilizer bar, connected to the chassis and both control arms, reduces body roll when cornering.
REAR SUSPENSION The rear suspension consists of torsion axle with shock absorbers and coil springs (see illustration). A stabilizer bar is incorporated into the rear axle assembly (it's integral with the axle beam and isn't removable).
STEERING The steering column incorporates a universal joint, and is connected to the steering gear by a second individual universal joint. The steering gear is mounted onto the front subframe, and is connected by two tie rods, with balljoints at their outer ends, to the steering arms projecting rearwards from the steering knuckles. Power-assisted steering is standard equipment. The hydraulic steering system is powered by a belt-driven pump, which is driven off the crankshaft pulley.

Subject: 1999, 2000, 2001, 2002, 2003, 2004, 2005 VW Golf, GTI, Jetta 4-cylinder gasoline and diesel service, maintenance, repair. ISBN-10: 156392708X | ISBN-13: 9781563927089 | Haynes 96018